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Hummer H1 (2002+). Manual - part 89

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Transmission/Transfer Case 5-155

05745159

FRONT OUTPUT SHAFT SEAL REPLACEMENT

Mark front propeller shaft and transfer case yoke for align-
ment reference.

Disconnect front propeller shaft at yoke. Retain U-bolts
and nuts (Figure 5-76).

Remove yoke nut (Figure 5-77).

Remove yoke and seal washer. Use tool J–8614-01 to
remove yoke if necessary.

Remove seal from front case bore with standard hook type
seal puller.

Coat outer edge of new seal with thin coat of RTV type
sealer.

Lubricate seal lip with transmission fluid and install seal
with tool J–38869.

CAUTION: The seal can be installed incorrectly. Be sure the
seal lip is toward the case interior.

Smooth seal contact surface of yoke with 320-400 grit
emery coated with transmission fluid. Then clean and
install yoke.

Install yoke seal washer.

10. Install and tighten yoke nut to 90-130 lb-ft (122-176 N•m)

torque.

11. Connect propeller shaft to yoke. Tighten U-bolt nuts to 13-

18 lb-ft (18-24 N•m) torque.

12. Check and top off transfer case fluid level if necessary.

Figure 5-76: Disconnecting/Connecting Front

Propeller Shaft

Figure 5-77: Front Output Shaft Yoke and Seal

Removal/Installation

TRANSFER CASE FLUID CHANGE

The transfer case fill and drain plugs are both located in the
rear case (Figure 5-78).

Correct fill level is to the lower edge of the fill plug hole. Rec-
ommended fluid is Dexron III.

Place vehicle on level surface. Or, if vehicle is raised on
hoist for fluid change, a drive-on hoist is preferred. Vehicle
must be level for accurate refill fluid level.

Remove drain and fill plugs and drain fluid into approved
container.

Install and tighten drain plug to 15-25 lb-ft (20-33 N•m)
torque.

Refill transfer case with Dexron III. Correct level is to
lower edge of fill plug hole.

Install and tighten fill plug to 15-25 lb-ft (20-33 N•m)
torque.

Lower vehicle, if on hoist.

Figure 5-78: Transfer Case Drain and Fill Plug

Locations

U-BOLT

YOKE

FRONT

PROPELLER

SHAFT

YOKE

NUT

SEAL

WASHER

YOKE

OIL SEAL

FILL

PLUG

DRAIN

PLUG

5-156

Transmission/Transfer Case

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TRANSFER CASE REMOVAL

Remove drain plug and drain oil from transfer case. Rein-
stall drain plug afterward.

Disconnect propeller shafts from transfer case.

Disconnect wiring harness connectors from vehicle speed
sensors range switch, and lock switch.

Remove wiring harness clamp and move harness away
from transfer case.

Disconnect vent line from transfer case (Figure 5-72).

Disconnect cooler hoses at transfer case (Figure 5-79).

Disconnect shift rod at range lever (Figure 5-80).

Remove guide cable and bracket (Figure 5-80).

Figure 5-79: Cooler Hose Connections

Support transfer case with jack. Secure transfer case to
jack with chain.

10. Remove nuts attaching transfer case to transmission

adapter (Figure 5-81).

Figure 5-80: Shift Rod Attachment

Figure 5-81: Separating Transfer Case From

Transmission

11. Slide transfer case rearward and remove it from under

vehicle (Figure 5-81).

TRANSFER CASE INSTALLATION

Mount transfer case on jack and secure with chain.

Apply bead of Loctite 518 to mounting surface of
transmission adapter.

Align and install transfer case on transmission. Tighten
transfer case attaching nuts to 37 lb-ft (50 N•m).

Remove jack.

Connect shift rod to range lever with washer and cotter pin
(Figure 5-80).

Install guide cable and bracket.

Connect transfer case vent line.

Connect cooler hoses to transfer case cooler fittings.

Connect front and rear propeller shafts to transfer case.
Tighten front shaft U-bolt nuts to 13-18 lb-ft (18-24 N•m)
torque.

10. Install vehicle speed sensor.

11. Install range and lock indicator switches.

12. Attach harness clamp to transfer case.

13. Connect wiring harness connectors to speed sensor and

switches.

14. Fill transfer case to bottom edge of fill plug hole with

Dexron III.

15. Check and adjust shift rod if necessary.

TRANSFER CASE

COOLER

HOSES

RANGE

LEVER

SHIFT ROD

GUIDE

CABLE AND

BRACKET

EXHAUST
BRACKET

FLAT

WASHERS

WAVY

WASHER

TRANSMISSION

ADAPTER

TRANSFER CASE

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Transmission/Transfer Case 5-157

05745159

TRANSFER CASE DISASSEMBLY AND
OVERHAUL

Remove vehicle speed sensor and both indicator switches.

Remove front output shaft yoke (Figure 5-82). Remove
yoke nut with suitable size socket and impact wrench.
Then remove seal washer and yoke.

Figure 5-82: Front Yoke Removal/Installation

Remove extension housing bolts. Then tap housing in
counterclockwise direction to break sealer bead
(Figure 5-83). Use plastic mallet to tap housing.

Remove extension housing (Figure 5-84).

Figure 5-83: Loosening Extension Housing

Figure 5-84: Extension Housing Removal

Remove rear retainer bolts. Then remove mainshaft
bearing snap ring (Figure 5-85).

Pry rear retainer upward at each lug with screwdriver
(Figure 5-86). Remove retainer after breaking sealer bead.

Figure 5-85: Mainshaft Snap Ring Bearing Removal

SEAL

WASHER

YOKE

NUT

YOKE

FRONT

OUTPUT

SHAFT

EXTENSION

HOUSING

PLASTIC

MALLET

REAR

CASE

REAR

RETAINER

EXTENSION

HOUSING

REAR

RETAINER

SNAP RING

5-158

Transmission/Transfer Case

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Figure 5-86: Rear Retainer Removal

Remove speedometer tone wheel and snap rings
(Figure 5-87).

Remove rear case attaching bolts and remove rear case
(Figure 5-88).

CAUTION: Loosen the rear case with screwdrivers positioned
in the slot at each end of the case. This will avoid damaging the
case sealing surfaces.

Figure 5-87: Speedometer Tone Wheel Removal/In-

stallation

Figure 5-88: Rear Case Removal

Remove oil pump, pickup tube, hose, and screen
(Figure 5-89).

10. Remove O-ring from oil pump inlet port (Figure 5-90).

Figure 5-89: Oil Pump Assembly Removal

LUG

SCREWDRIVER

REAR

RETAINER

MAINSHAFT

SNAP RING

TONE WHEEL

SNAP RING

REAR

CASE

REAR

CASE

OIL

PUMP

OIL PUMP

OIL PICKUP

TUBE

HOSE

OIL SCREEN

REAR CASE

Content .. 87 88 89 90 ..